Method of upholstering

ABSTRACT

A METHOD OF UPHOLSTERING A CHAIR OF ALMOST ANY SHAPE WITHOUT SEAMING WORK BY EMPLOYING A LINING MATERIAL WHICH IS AIRTIGHT AND FITS THE TEXTILES OF UPHOSTERY MATERIALS. THE LINING MATERIAL ALSO EXPANDS AND CONTRACTS WITH THE SURFACE OF THE UPHOLSTERY MATERIAL DURING THE PROCESS OF PNEUMATICALLY CONTOURING THE UPHOLSTERY TO THE DESIGN CONFORMATION AND FIXING THE UPHOLSTERY IN THIS CONDITION.

June 29, 1971 KATsUYA sHlRAKAwA METHOD OF UPHOLSTERING 2 Sheets-Sheet 1Original Filed July 22, 1966 a o llmbllllf: 33

Mv KT/mmf? June 29, 1971 KATsuYA sHlRAKAwA 3,589,967

' I I METHOD OF UPHOLSTERING Original Filed July 22, 1966 2 Sheets-Shetl l-ff" s Unted States Patent O `ice METHOD OF UPHOLSTERING KatsuyaShirakawa, Tokyo, Japan, assiguor to Junich Shirakawa, Tokyo, JapanContinuation of application Ser. No. 567,097, July 22,

1966. This application Oct. 20, 1969, Ser. No. 867,855 Int. Cl. B29c17/00 U.S. Cl. 156-287 8 Claims ABSTRACT OF THE DISCLOSURE A method ofupholstering a chair of almost any shape without seaming work byemploying a lining material which is airtight and fits the textiles ofupholstery materials. The lining material also expands and contractswith the surface of the upholstery material during the process ofpneumatically contouring the upholstery to the design conformation andfixing the upholstery in this condition.

This application is a continuation of commonly assigned application,Ser. No. 567,097 filed July 22, 1966, now abandoned.

This invention relates to a method of upholstering and, moreparticularly, to an automatic mechanized technique for upholsteringchairs.

In the past, a number of approaches have been proposed for upholsteringchairs but in the main most of them were basically manual operations.With the advent of modern and fashionable chairs of styles ranging fromstreamlined to the somewhat complex styles included in which is smockingor like patterns, it has become increasingly difficult to upholster suchchairs manually because of the tedious nature of the work as well as theattendant cost of time and effort. Heretofore, machinery to perform thistype of work has been virtually non-existent.

It is, therefore, a principal object of this invention to upholster theshell or frame substantially automatically and by machinery; and toupholster in this fashion by means of this invention chairs or otherpieces of furniture.

Another object is to provide an automatic upholstering technique of theabove type whereby it is now possible to incorporate selected patternson the surface of the upholstery to obtain the desired contour of theupholstery and aesthetic or ornamental effect.

Brieiiy stated, the present invention utilizes a vacuumforming techniquein which the intended frame to be upholstered is placed in a vacuumchamber. In accordance with one embodiment ofthe invention, the selectedcushioning material is initially applied to the frame and suitablysecured thereto as, for example, by means of an interposed bondingagent. The selected upholstery or covering material is, preferably,conditioned to be substantially airtight and is placed over thecushioning material and adhered to the peripheral edges of the frame bymeans of a suitable interposed bonding agent. A vacuum is then drawninto the chamber to remove or expire the air between the upholsteringmaterial and the shell to draw the upholstery into relatively tightengagement with the cushioning material. Depending upon the effectsdesired, the Vacuum drawn can be varied and in order to render theupholstery pliable and provided with some elasticity to conform to thedesired contour, heat may be supplied to the vacuum chamber during thevacuum-drawing cycle.

In accordance with another embodiment of the invention, a selectedpattern is automatically incorporated into the upholstering by utilizinga frame form as, for example, that which will produce a smocking rquilted pattern. Air is exhausted between this pattern frame andPatented June 29, 1971 the basic frame of the particular piece offurniture which will have had already sealed to the periphery thereofthe film of upholstery material preferably of a substantiallyair-impervious nature. The air is exhausted between the shell frame andform frame in such a manner that the upholstery film is drawn or pulledagainst the form frame and bulged or expanded into arcuateconfigurations within the form frame openings. In the event heat isrequired to render the film more pliable or expansible in order toobtain the desired conformity with the form frame, hot air can beintroduced at a controlled pressure equal to or less than the vacuumbeing drawn. When the desired conformity of the film with the form framehas been obtained, an expansible foam type of material may then beintroduced between the shell frame and the film. Under controlledexpansion conditions, the foam will iill the Void or space between theiilm and shell frame. An adhesive may have been initially placed on theinner surface of the film such that when the foam material has set up,the tilm will be adhesively secured thereto to retain the desiredpattern of upholstery. As is the case with the previous embodiment, thelining may then be applied to the rear of the shell frame and bottomportions thereof by drawing a vacuum between the shell frame and liningin order that an interposed bonding material may secure these two partstogether.

A further embodiment of the invention contemplates following either ofthe above techniques fbut placing another material desired forupholstery such as Woven goods or the like along with the essentialythin air-impervious l-m as a laminated structure. In this manner notonly can selected patterns be obtained but selected goods as well forthe covering upholstery material while still maintaining the automatedprocess for upholstering.

Other objects and advantages will become apparent from the followingdetailed description which is to be taken in conjunction with theaccompanying drawings illustrating several somewhat preferredembodiments of the invention and in which:

FIG. l is a diagrammatic side elevational view of vacuum chamber havinginlet and exhaust ports as well as heating elements together with meansfor supporting a shell frame to which the upholstery material and lininghas been peripherally secured prior to the initiation of the vacuumpulling operation;

FIG. l is a cross-section taken along the line 1-1 of FIG. 1;

FIG. 2 is a similar side elevational view following the vacuum pullingoperation and heat application step showing the upholstery material andlining secured and in conformity with the shell frame and cushioningmaterial;

FIG. 2' is a cross-section taken along the line 2-2 of FIG. 2;

FIG. 3 is a side perspective View with certain parts broken away andremoved of the apparatus and internally mounted components of FIG. 2;

FIG. 3' is a front perspective view of FIG. 3;

FIG. 4 is a front perspective View of an upholstered chair made inaccordance with the embodiment of FIGS. l to 3;

FIG. 5 is a diagrammatic side elevational view of another embodiment ofthis invention in which selected patterns may be incorporated into theupholstering material which, as illustrated, may be in the nature ofsmocking with a multiple chamber being shown having exhaust and inletports as well as means for supporting ya shell frame as well as a formor pattern frame having interposed therebetween the upholstery filmwhich ultimately conforms to the yselected pattern of the form frameupon pulling of a vacuum between the frames with means also being shownfor automatically applying foam type of cushioning material togetherwith means for applying a lining to other parts of the shell frame;

FIG. isa cross-section of FIG. 5;

FIG. 6 is a similar side elevational view showing the upholsterymaterial conforming to the form frame upon the pull of Vacuum betweenthe form frame and lshell frame;

FIG. 7 is an enlarged fragmentary perspective view of an exemplary formframe adapted to produce a smocking type of pattern on the upholsterymaterial; and

FIG. 8 is a front perspective View of a chair made in accordance withthe embodiment of FIGS. 5 to 7 having incorporated therein the selectedsmocking pattern for the upholstery.

Referring now to the embodiment of FIGS. l to 4, the particular memberto be covered or upholstered is a chair shell frame 10 which may be madeof wood or any one or combination of available resins or syntheticmaterial such as polyesters and glass fiber. The frame 10 will include,for example, a back 12, a seat 14 and a pair of arms 16. Cushioningmaterial 18 will initially be placed on the forward side of the back 12and upper side of the base 14 and perhaps on the interior base of thearms 16. This cushioning materi-al is ordinarily elastic and sufficient-'ly porous to have Ventilating properties and may be selected from anyone of a number of materials used for such purposes such as Ifoam rubberor urethane foam. The cushioning material 18 is initially adhered orsuitably connected to the surfaces of the shell frame 10 by a bondingagent having aflinity for the cushioning material and shell frame. Theselected upholstery material 20 is initially placed or draped over thecushioning material 18 and over such parts of the remainder of the frame12 to be covered thereby and is suitably connected along its peripheryto surfaces of the frame 12in any one of a number of means andpreferably in an airtight fashion as, for example, by means of asuitable bonding agent or other equivalent means. Interior surfaces ofhte upholstery material 20 have applied thereto a suitable bonding agenthaving ainity for the selected cushion material 18. In actual practiceit was found to be desirable that the upholstery material 20 hesubstantially airtight and somewhat elastic. Commercially availablevinyl resin sheet material has proven to provide satisfactory resultseither as the upholstery material or as a lining for the selectedupholstery material which may assume any one of a number of formsincluding woven goods which are initially suitable adhered to the vinylmaterial. Other surfaces of the frame 10 particularly the back 12 mayhave applied thereto a substantially airtight end elastic sheet materialserving as the lining 22 which is also initially secured at itsperiphery to the associated portions of the shell frame 10 as, forexample, by means of a suitable bonding agent. The interior surfaces ofthe lining 22 will also have applied thereto a bonding agent havin-gainity for the associated surfaces of the shell frame 10 to which itwill ultimately be placed in surface-to-surface relationship. Forpurposes of which will become apparent, the shell frame 10 is providedwith an outlet opening or port 24 and an inlet or Ventilating opening 26the latter of which may be free to open and close by means of aflap-type of valve 28, for example.

The shell frame 10 and assembled cushioning material 18, upholsterymaterial 20 and lining 22 is then placed in a vacuum chamber 30 definedby an outer housing 32 constructed in a substantially airtight mannerand which may also have one or more access doors for purposes of placingthe frame 10 with assembled materials in the vacuum chamber 30. Theinterior of the housing 32 may be provided with suitable heating meanssuch as the coils 34 which may be thermostatically controlled to assurethe proper amount of heat in the vacuum chamber 30. In addition, theinterior of the housing 32 is provided with one or any number ofsupports 36 for supporting the shell frame 10 and assembled materialswithin the vacuum chamber 30. A conduit 38 which may be of the flexibletype is suitably connected with the exhaust opening 24 of the shellframe 10 by any one of a number of suitable coupling means. The conduit38 extends exteriorly of the housing 32 and is coupled with a suitablevacuum source 40 such as the usual air compressor. The housing 32 isalso provided with a valve-controlled outlet 42 which, in turn, iscoupled with another compressor 44 of the hypotonic type.

Assuming for the moment that the cushion material 1'8 has beenadhesively secured to lthe shell frame 10', a 'bonding agent has beenapplied either to the interior surfaces of the upholstery 20 or on theouter surface of the cushioning material 18 which bonding agentpreferably possesses some degree of elasticity and which may be selectedfrom the class of gum arabic materials, and the edges or periphery ofthe material 20 has been secured in an airtight fashion to theperipheral surfaces or edges of the shell frame 10 by the use of thesame or other suitable binding agent, the shell frame 10 and assembledmaterial will be placed in the Vacuum chamber 30 and supported thereinby the supports 36. It should be understood that the present inventionalso contemplates assembling these parts Within the vacuum chamber 30.The exhaust conduit 38 is suitably coupled with the exhaust opening 24and thereafter the compressor or vacuum pump 40 is set into operation.In accordance with a successful application of the invention, the vacuumpump 40 drew a vacuum of 'between 7 to 10 atmospheres. Under thecircumstances, the air between the cushioning material 18 and theupholstery 20 is expired or exhausted through the porous or ventilatablecushion material 18 through the exhaust port 24 out through the exhaustconduit 38. The upholstery material 20 is, accordingly, forced intoengagement with the cushion material 18 and by means of the interposedbonding agent is adhered directly thereto.

In order to obtain optimum bonding or adherence between the cushioningmaterial 18 and the upholstery material 20, -it is advisable to assure afresh air supply otherwise the air within the vacuum ychamber 30 will'become thin and stale thereby reducing the effectiveness of the bondingagent. In this connection, the hypotonic compressor or pump 44 comesinto play and is set into operation following opening of the Ventilatingopening or port 42. In accordance with the mentioned successfulapplication of this invention, fresh air was introduced into the vacuumchamber 30 by means of the hypotonic compressor at approximately 0.5 to1.0 atmosphere to thereby reduce the generated vacuum by about 20%.

Assuming also -that the lining material 22 has been applied toperipheral surfaces of the shell frame 10 prior to the operation of thevacuum pump 40 and that a suitable bonding agent has either been appliedto the interior surfaces of the lining material 22 or, for that matter,to the opposed surfaces of the shell frame 10, the lining 22 will alsobe forced into engagement and conformity with the opposed surfaces ofthe shell frame 10 and adhered thereto by means of the interposedbonding agent. The resultant condition of the shell frame 20 andassociated materials is depicted in FIG. 2.

In order to assure the desired confirmation of the upholstery material20 and lining material 22 with the shell and cushioning material appliedthereto and particularly when using a vinyl type of material for theupholstery and liner, the vacuum chamber 30 is heated by means of theheating coils 34 with suicient amount of heat to render the upholsteryand liner material slightly pliable and elastic. Of course, thegenerated heat should not 'be sufficient to degrade any of the materialsto be assembled and, therefore, the amount of heat supplied to thevacuum chambre 30 will depend upon the materials therein. With this inmind, the time that the chair components remain in the vacuum chamber 30will vary 4but generally will be between ive to ten minutes. After theexpiration of a predetermined period of time, the upholstery material 20will be adhered to and in conformity with the cushion material 18 andthe lining material 22 will be adhered to and in conformity with theshell frame 10. The air introduced into the vacuum `chamber 30 by thecompressor 44 is then stopped and the air exhausted from the vacuumchamber 30 by means of the vacuum pump 40 is also stopped. The assembledparts are then permitted to cool and dry either in the vacuum chamber 30or exteriorly thereof. The cycle and process is then resumed whendesired for purposes of upholstering another unit.

Referring now to the embodiment of the invention illustrated in FIGS. to8, it will initially be appreciated that a predetermined pattern,configuration or contour of upholstery is contemplated by thisinvention. In accordance with the illustrated embodiment, a smockingtype of upholstery pattern is obtained. Thus, an outer housing 50encloses an inner housing 52 -defining a vacuum chamber 54. The selecteddentiform or pattern frame 56 having projections or teeth 58 at theintersection of the frame members is suitably mounted interiorly of theinner housing 52 by suitable supporting means 60 and in such a mannerthat the dentiform frame 56 is placed into engagement with an innersubstantially imperforate frame l62. and suitably spaced therefrom bymeans of the spacers 64 which cooperate in providing air passage betweenthe dentiform frame 56 and inner frame 62. The inner frame 62 will beprovided with a valvecontrolled air vent 65 controlled by means of aflap type of valve. The shell frame 66 having only the selectedupholstery material -68 and the lining material 70 adhered thereto alongtheir respective peripheries is mounted in the vacuum chamber 54 bymeans of the supports 72. The peripheral securement of the upholsterymaterial 68 and lining material 70 to the shell frame 66 is similar tothat described in connection with the previous embodiment and as is thecase with that embodiment, either the surfaces of the shell frame 66 orinner surfaces of the upholstery material 68 and lining material 70 willhave applied thereto a suitable bonding agent. Where found to bedesirable or necessary, all of the surfaces may have applied thereto asuitable bonding agent.

At the initiation of the cycle of operation of this embodiment, thecomponents will assume the form schematically depicted by FIG. 5. Theair between the inner housing 52 and inner frame 62 Will be exhausted orexpired by means of the vacuum pump 74 through the interconnectingexhaust conduit 76. The upholstery material which is of an imperforatenature will be drawn into conformity with the dentiform frame 56 as aresult of the vacuum now being drawn through the opening 65 in the innerframe 62.

In order to facilitate the confirmation of the upholstery material 68 tothe desired pattern, the present invention contemplates rendering thecushioning material more pliable and elastic by introducing heated airthrough the inlet opening 78 in the shell frame 66 through the inletconduit 80 extending from the hypotonic compressor 82. In accordancewith a successful application of the invention, the heated air wasintroduced for approximately one minute at a temperature of 40 C.

Thereafter, in order to maintain the desired generated shape of theupholstery material 68, an expandible foam type of material, as forexample, of the urethane foam type 84 is injected between the upholsterymaterial and shell frame 66 through the shell frame opening 78 from thesource 86. In order to facilitate the desired expansion of the foammaterial 84 in accordance |with the successful embodiment, thetemperature of the air introduced through the opening 78 at relativelyreduced pressure was maintained at about 25 to 26 C. and applied forabout fifteen minutes. The desired extent of expansion of the urethanefoam material 84 was then accomplished.

The air between the shell frame 66 and lining material 70 is thenexpired or exhausted by pulling a Vacuum through the exhaust conduit 88communicating in the space therebetween. The other end of the conduit 88is coupled with a vacuum pump 90. Under the circumstances, the liningmaterial 70 will be drawn into conformity with the shell frame 66 andsecured thereto by means of the interposed adhesive. The valvecontrolled vent opening 92 having the conduit 94. extending therefrom toanother hypotonic compressor 96 assures the introduction of a freshsupply of air at reduced pressures to obtain optimum effectiveness ofthe bonding agents employed for securing the lining material 70 to theshell framev 66.

As will be appreciated by those skilled in the art, the securement ofthe lining material 70 'to the shell frame 66 can be accomplished eitherat a separate time or simultaneously with the formation of theupholstery material 68 to the desired pattern.

Thus, it will be apparent that it is now possible to upholstersubstantially any shape or shell without seaming work and to completeupholstering without seams and to secure the assembled parts to oneanother relatively rapidly and automatically. In order to assure aneffective and efficient operation in accordance with this presentinvention, the upholstery material, whether it be material 20 ormaterial 68, is carefully selected and processed beforehand to assureits desired confirmation and its softness in the finished upholsteredunit. The outer surface of the upholstering material may be either nylonor material of any other suitable yarn which is either jerseyed orknitted. This material is preferably lined with an imperforate layersuch as very thin vinyl film pasted to the backside of the surfacingmaterial 'with a suitable Ibonding agent which again may be a suitableand compatible type of gum arabic of either a methyl, ether, or ketonederivative. Of course, the surfacing material may also be selected fromwoven goods. In accordance 'with successful applications of the presentinvention, vinyl film of approximately 0.14 millimeter thickness andcomposed of vinyl chloride '(65%), plasticizer (33%), and stabilizer(2%) has afforded excellent properties of stretch, elasticity andcontraction for purposes of furthering the invention.

I claim:

1. A method of upholstering a piece of furniture comprising:

providing a shell frame for defining the piece of furniture to beupholstered and the shell frame having certain parts to be upholstered;

applying a substantially air-impervious flexible covering sheet ofmaterial having a peripheral edge over certain parts of the shell frameand adhering the sheet to the frame;

providing a chamber defined by a housing having a reclosable opening;

placing the shell frame with applied covering sheet in a chamber throughthe opening, supporting the frame therein and reclosing the opening;

providing a substantially air-impervious connection between theperipheral edge of the covering material and the shell frame; subjectingthe interior of the housing and the chamber to a temperature andpressure controlled atmosphere;

subjecting the covering material to air pressure differential whileunder the infiuence of the controlled atmosphere to draw the coveringmaterial into a predetermined conformation; and

fixing this conformation of the covering material.

2. The invention -in accordance with claim 1 wherein a bonding agent isapplied intermediate said coveringmaterial and frame prior to theapplication of the air pressure differential.

3. The invention in accordance with claim 1 wherein a cushioningmaterial is interposed between the shell frame and covering material.

4.`The invention in accordance with claim 3 wherein the cushioningmaterial is preformed and adhered to the surfaces of the shell frameover which the covering material is to be applied and a bonding agent isapplied between the cushioning material and the covering material priorto the application of the covering material over the shell frame and theair pressure differential is in the form of a vacuum to draw air betweenthe shell frame and covering material to thereby draw the coveringmaterial into conformity with the opposed surfaces of the cushioningmaterial and shell frame.

5. The invention in accordance with claim 4 wherein during thevacuum-drawing step, heat is applied to render the covering materialpliable and elastic to cause the covering material to conform with theopposed surfaces of the cushioning material and shell frame.

6. I'he invention in accordance with claim 1 wherein said coveringmaterial includes a surface upholstery material, a lining membrane, andadhesive means to bond said lining membrane to said surface upholsterymaterial thereby reinforcing said surface upholstery material andmaintaining the flexibility of said lining membrane.

7. The invention in accordance with claim 6 wherein the coveringmaterial is a nylon surface upholstering material and said liningmembrane is a lm-like vinyl which is between 0.05 and 0.5 millimeters inthickness and is composed of vinyl chloride 65%, plasticizer 33%, and

8 stabilizer 2% for the nylon surface upholstery material. 8. Theinvention in accordance with claim 1 wherein fresh air circulatedbetween the covering material and shell frame at reduced pressures tocooperate in xing the conformation of the covering material and itsrelative relationship with the shell frame.

References Cited UNITED STATES PATENTS BENJAMIN R. PADGETT, PrimaryExaminer G. G. SOLYST, Assistant Examiner U.S. Cl. X.R.

